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ICTD International Centre for Training and Development

Rolling Mill Design and Operations

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Description

This five-day, instructor-led course is designed to improve mill related engineers the basic skills on rolling mill parameters calculation for mill design, development and operation. The course covers metal deformation in the roll gap, force, torque and power requirements, and temperature and microstructure evolution during rolling and controlled cooling. Fundamentals on rolling mill design and development are introduced. Primary focus is on the rolling process modeling and application of the models in the design and development. Students will perform various Lab projects on mill parameters calculation, and run over a dozen of rolling mill design and development programs hosted in order to enhance their understanding on mill design fundamentals, and to improve their design and development skills. The training consists of twenty modules. Each module has Lessons on fundamental topics, and a Lab for performing hands-on excises. The work on steel rolling process modeling and mill design requires large amount of hands-on calculation and data processing, so this type of Lab excises is necessary for high-quality training.

Course Objectives

Upon successful completion of this course, the delegates will be able to:

  • Better understand rolling process as an integration of mechanical, metallurgical and control engineering systems
  • Use models to determine major rolling process parameters
  • Understand roll pass design fundamentals and Use roll pass program to perform design and development
  • Use advanced roll pass programs to design high-quality roll pass schedules and to improve existing ones
  • Understand flow stress and mean flow stress, and perform basic calculation on flow stress and mean flow stress
  • Manually calculate rolling force, torque and power, etc., and use software to calculate the force, torque and power, etc. for various groove sequences in various rolling conditions
  • Know general methods for rolling process modeling and understand strengths and limitations for each method
  • Understand that steel rolling is a dynamic metallurgical process, with both softening and hardening mechanisms, and rolled steel properties are affected by many process parameters
  • Have knowledge on numerical models (FEM, FDM) and use programs to perform some numerical simulations
  • Know the temperature profile along the rolling production line and over the stock crosssection
  • Simulate microstructure evolution during rolling by applying internet-based simulation program
  • Understand the significance, function and development progress of Level 2 system; know that quality of the control system is one of the key indicators for the equipment technology level
  • Know Level 2 Model functions, architecture and future development

Agenda

Day 1

Fundamental Principles of Metal Rolling

  • Range of Billet and Rolled Product Sizes
  • Steel Grades and Steel Qualities
  • Classification of Rolling Mills for Producing Rebars
  • Main Line of a Rebar Rolling Mill

Heating of Metal Before Rolling

  • Function of Metal Reheating before Rolling
  • Bases of Selection of Reheating Temperature
  • Effect of Reheating on Billet Properties
  • Billet Temperature Control
  • Design and Performance of Reheating Furnace

Day 2

Fundamentals of Roll Pass

  • Types of Rolling Passes for Producing Rebars
  • Components of Rolling Passes
  • Rolling Gap Setting
  • Stand Drafting and Coefficient of Deformation in Rolling Stands

Breakdown Sequences

  • Box Pass Sequence - Design and Calculation
  • Oval - Square Sequence
  • Design of Square and Oval Passes
  • Distribution of Elongation among Passes
  • Characteristics and order of Calculation for Producing Rebars
  • 4Oval - Round Sequence
  • Pass Cooling and Bar Shape

Day 3

Factors Affecting Precise Rolling of Rebars

  • Rigidity of Working Rolling Stand
  • Rolling Temperature
  • Temperature of Working Rolls
  • Wear of Rolls and Other Stand Components
  • Guides
  • Looping and Interstand Tension

Calculation of Rolling Parameters

  • Calculation of Rolling Load
  • Determination of Area under Compression
  • Resistance to Deformation in Hot Rolling of Rebars
  • Calculation of Rolling Torque and Power Requirements
  • Defects of Finished Rebars and How to Prevent Them

Day 4

Complete Example of Roll Pass Design Calculations for Rebars

  • Procedure of Calculations
  • Determination of the Number of Passes
  • Distribution of Reduction and Elongation among Passes
  • Designing the Dimensions of Different Passes
  • Check for Areas and Biting Condition

Technology of Rolling Round Rebars

Day 5

Finishing Operations on Rolled Rebars

  • Cutting and Finishing
  • Cobbles
  • Rebar Quenching System
  • Prime and Non-Prime Products

Rebar Rolling Mill Productivity

  • Rolling Mill Output
  • Factors affecting Rebar Rolling Mill Productivity
  • Mill and Time Utilization Coefficients
  • Rolling Mill Chart
  • Metal Consumption in Rebar Rolling Mills
  • Safety Regulations in Rebar Rolling Mills

Who should attend

This course is designed for rolling mill design, development and operation engineers who have basic experiences on steel rolling and rolling mills, and want to enhance knowledge and skills on high quality mill design, development or operation.

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